Thermal packaging system

ABSTRACT

The present invention is an apparatus, method and system to thermally package an item having at least one container substantially filled with an alcohol, wherein said alcohol undergoes a phase change.

FIELD OF THE INVENTION

The present invention relates to packaging systems. More particularly,the present invention relates to thermal packaging systems for productsthat must be packaged in a temperature-controlled environment.

BACKGROUND OF THE INVENTION

The use of refrigerants to keep items cool is widespread, both fortransportation of heat sensitive or heat damageable products and forlong term storage of the products. Refrigerators and refrigeratedtransport systems can be used for storage and transportation of largescale products, but may not be available for small scale products suchas short haul delivery systems, airline transportation, and home andrecreational cooling of foods, beverages and the like.

The use of ice, dry ice, or blue ice to keep products at a cooltemperature has been used extensively for many years. For example, thegeneral public widely uses insulated containers packed with ice tomaintain foodstuffs and beverages cool when camping, travelling or onpicnics and the like. Ice is also used commercially to pack foodstuffs,flowers, plants and the like for transportation and storage until soldor until placed in a refrigerator. Ice is also used in the medical fieldto reduce trauma, swelling and pain from injuries of all kinds, and totransport and store blood, tissue, organs, pharmaceuticals and the like.The use of ice, dry ice, or blue ice as a coolant material serves as apreservative and inhibits the growth of harmful microorganisms.

The major drawback to the use of ice as a coolant material is that itmelts and is no longer an effective packaging material. The melted iceis easily contaminated by microorganisms which, since it will be inintimate contact with the products it is protecting, is also liable tocontaminate the products. The items may also be damaged by getting wet.The melted ice may also allow the products to move or slosh around inthe container, risking damage by impact with the walls of the container.Moreover, the container itself must also be waterproof or the water andthe products will break out of the container.

Dry ice also has some disadvantages. It is converted into CO₂ with timeand thus the gas must be dissipated and the product will not be packedagainst movement in its container or be kept cool. Both water and dryice can be used only once, adding to the expense of thermal storage.

Blue ice may be used repeatedly by refreezing the contents of the bag orblock. However, blue ice is brick hard when frozen into a solid blockand becomes soft and pliable as the material melts within the bag.

Ice, dry ice, and blue ice may be used to keep items or products cool,however, a user has no control over the temperature of the container orthe products. Currently, there is no way to maintain the temperature ofproducts unless a refrigerator or refrigerated transport system is used.Moreover, when used, the ice, dry ice, and blue ice move around withinthe package that may create temperature variances within the packaging.Thus, some parts of the products may be cool while other parts are warm.

Thus, there is a need for an apparatus and method that allows a user tomaintain a constant known temperature over an extended period of time ina container without the use of refrigerators or refrigerated transportsystems at an economical cost. Moreover, there is a need for a reusableapparatus that allows a user to maintain a constant known temperature ina container with little to no temperature variances within thepackaging.

BRIEF DESCRIPTION OF THE INVENTION

The present invention is an apparatus, method and system to thermallypackage an item having at least one container substantially filled withan alcohol, wherein said alcohol undergoes a phase change.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated into and constitute apart of this specification, illustrate one or more embodiments of thepresent invention and, together with the detailed description, serve toexplain the principles and implementations of the invention.

In the drawings:

FIGS. 1A, 1B, and 1C illustrate examples in which the phase changematerial may be packaged.

FIGS. 2 and 2 a illustrate top views of an example to releasably lockthermal packs together in accordance with an embodiment of the presentinvention.

FIGS. 3 and 3 a illustrate top views of an example to releasably lockthermal packs together at a corner in accordance with an embodiment ofthe present invention.

FIG. 4 illustrates a system in accordance with an embodiment of thepresent invention.

FIG. 5 is a block diagram of a method in accordance with an embodimentof the present invention.

DETAILED DESCRIPTION

Embodiments of the present invention are described herein in the contextof a thermal packaging system. Those of ordinary skill in the art willrealize that the following detailed description of the present inventionis illustrative only and is not intended to be in any way limiting.Other embodiments of the present invention will readily suggestthemselves to such skilled persons having the benefit of thisdisclosure. Reference will now be made in detail to implementations ofthe present invention as illustrated in the accompanying drawings. Thesame reference indicators will be used throughout the drawings and thefollowing detailed description to refer to the same or like parts.

In the interest of clarity, not all of the routine features of theimplementations described herein are shown and described. It will, ofcourse, be appreciated that in the development of any such actualimplementation, numerous implementation-specific decisions must be madein order to achieve the developer's specific goals, such as compliancewith application- and business-related constraints, and that thesespecific goals will vary from one implementation to another and from onedeveloper to another. Moreover, it will be appreciated that such adevelopment effort might be complex and time-consuming, but wouldnevertheless be a routine undertaking of engineering for those ofordinary skill in the art having the benefit of this disclosure.

The present invention is an apparatus, method, and system that allows auser to maintain a constant known temperature over an extended period oftime in a container with little to no temperature variances within thecontainer. The present invention utilizes the phase change properties ofvarious phase change materials, specifically of alcohols. Differentmixtures, cuts and blends of alcohols may be used. In an embodiment ofthe present invention, the alcohols used have a purity of between90%-100%. However, those of ordinary skill in the art will now realizethat any linear or branched alcohol of varying purity may be used in thepresent invention. Phase change is the property of a material by whichwhen turning from solid to liquid (or vice versa), energy is absorbed orreleased without a change in temperature of the material. The phasechange material, used in the present invention may change from solid toliquid (and vice versa) at different temperatures. By way of example,blood platelets and biological tissues are chemically unstable in hightemperatures and must be maintained between 20° C. and 24° C.1-Dodecanol, a linear alcohol, has a phase change at about 20° C.-24°C., an ideal temperature to maintain the blood platelets or tissue in acontainer. The present invention may be used to control the temperatureof such products during transport by confining the temperature of theproduct within a predetermined range. The use of linear or branchedalcohols allow for a relatively constant temperatures as it undergoes aphase change. This permits light weight packaging with the maintenanceof temperatures in narrow, pre-selected ranges over extended periods oftime.

The phase change material used in the present invention may be analcohol such as a linear alcohol or branched alcohol. By way of exampleonly, and not intended to be limiting, examples of linear alcohols thatmay be used in the present invention are 1-Dodecanol and 1-Decanol. Inan embodiment of the present invention, the alcohol may have betweenabout 6 to 20 carbon atoms.

1-Dodecanol is also known as Dodecyl alcohol, lauryl alcohol, Duodecylalcohol, and Lauric alcohol. 1-Dodecanol is a saturated fatty alcoholhaving a chemical formula of:CH₃CH₂CH₂CH₂CH₂CH₂CH₂CH₂CH₂CH₂CH₂CH₂OH

1-Dodecanol is a colorless solid and liquid and is insoluble in water.Its phase change property at about 20° C.-24° C. allows for a user tomaintain the temperature of products at a known temperature of around20° C.-24° C. 1-Dodecanol has a low toxicity, is non-hazardous, and isrelatively inexpensive.

1-Dodecanol is currently used primarily as a chemical intermediate forthe production of n-Dodecyl sulfate salts, and in the manufacture ofn-Dodecyl ethoxylates. It is also used in synthetic detergents, lubeadditives, pharmaceuticals, as a flavoring agent in foods, cosmetics,rubber, textiles, lotions and creams, and perfumes. By way of example,1-Dodecanol has been found in fillers and insulating materials for thebuilding industry, part of foaming and surface-active agents forcleaning purposes, and in metal refining and processing. It has alsobeen found in ice cream, candy, baked goods, chewing gum, and syrups.However, until now, 1-Dodecanol has never been used or known as a phasechange packaging material to package temperature sensitive products.

1-Decanol is also known as capric alcohol, royaltac, decanol, n-decanol,decyl alcohol, caprinic alcohol, and n-decyl alcohol. 1-Decanol is asaturated fatty alcohol having a chemical formula of:CH₃CH₂CH₂CH₂CH₂CH₂CH₂CH₂CH₂CH₂OH

1-Decanol has a phase change at about 2° C.-8° C. that allows for a userto maintain the temperature of products at a known temperature of around2° C.-8° C. Thus, 1-Decanol may be used to protect products between 2°C. to 8° C., which is the required temperature for many pharmaceuticalproducts.

Similar to 1-Dodecanol, 1-Decanol is currently used in household laundrydetergents, shampoos, cosmetics, and industrial processes, lubricantadditives, and germicidal and fungicidal products, and fabric softeners,just to name a few uses.

FIGS. 1A, 1B, and 1C illustrate the various containers in which thephase change material may be packaged. The phase change material may besubstantially contained in various containers or packs such as bags,shaped containers (a square container is illustrated herein) 100, gelblankets 102, bottles 103, sponges and other porous materials,recirculating systems, single and multi-wall plastic assemblies, orother similar containers. The phase change materials may be placedwithin the containers through an opening in the containers. Thecontainers may be made of various materials such as high-densitypolyethylene, low-density polyethylene, or any other similar materials.Those of ordinary skill in the art will now realize that any materialsthat are chemically compatible and stable with the phase change materialmay be used.

The container and the phase change material may be reusable, thusallowing for a low cost packaging solution. Moreover, the thermalpackaging system is low in weight and volume and allows for an equaldistribution of temperature within an outer container used to house thephase change material and products.

Releasable locking means on the container may protect the products fromtemperature variances within the packaging and may also protect theproducts against damage from shock and vibration during transit. FIGS.2, 2 a, 3, and 3 a illustrate top views of an example to releasable lockthe thermal packs together in accordance with an embodiment of thepresent invention. FIGS. 2 and 2 a illustrate an example to releasablylock two containers together in a side-by-side configuration. Containers200 and 202 may have a connector 204 a, 204 b, 206 a, 206 b on each sideof containers 200 and 202. Connectors 204 a and 206 a may be connectedusing a releasable lock 208 whereby connectors 204 a and 206 a mayslidably fit into grooves in releasable lock 208. Releasable lock 208may have a bottom (not shown) to prevent connectors 204 a and 206 a fromsliding out. The releasable locking means helps to thermally protect theproducts from temperature variances by preventing the containers fromsliding, changing positions or shifting around each other. This furtheraid in the ability for greater validation of the products for transit.

FIGS. 3 and 3 a illustrate an example to releasably lock two containerstogether at a corner. Containers 300 and 302 may have connectors 304 a,304 b, 306 a, 306 b on each side of containers 300 and 302. Similar toFIG. 2 a, a releasable lock 308 may be used to connect connectors 304 aand 306 a whereby connectors 304 a and 306 a may slidably fit into thegrooves in releasable lock 308. Releasable lock 308 may have a bottom(not shown) to prevent connectors 304 a and 306 a from sliding out.Releasable lock 308 is a V shape that allows for containers 300 and 302to be positioned at an angle relative to each other.

Those of ordinary skill in the art will now realize that there may beother ways to releasably lock the containers together and prevent themfrom easily coming apart such as the use of Velcro, snaps, and othersimilar releasable locking means. Moreover, the releasable locks may bepositioned on any surface of a container to prevent possible movement ofthe containers in any direction. For example, the releasable locks maybe positioned on a front and back surface of the container such that thecontainers may be stacked upon each other. Furthermore, FIGS. 2 and 3illustrate two releasable locks on the containers. However, that is notintended to be limiting since any number of releasable locks may beplaced on the containers as is necessary such as one or three.

The present invention provides for a system of using the phase changematerial as illustrated in FIG. 4. The items 404 to be thermallyprotected are packaged in a first container 400. By way of example andnot intended to be limiting, the items 404 may be blood platelet bags.The first container 400 may be a plastic bag, or the like. An absorbingpad 402 may be placed below the items 404 to provide for addedprotection from wetness or shock. The first container 400 may or may notbe sealed.

A second container 406 may be used to house the first container 400.Thermal packs 408 a, 408 b, 408 c, 408 d may be positioned within thesecond container 406 above and below the first container 400. Thethermal packs may be substantially filled with 1-Dodecanol to keep theitems 404 at a constant temperature of about 20° C.-24° C. Although thethermal packs are illustrated as brick shaped containers, those ofordinary skill in the art will now realize that other shapes may beused. Moreover, as described above, the thermal packs may be connectedtogether in the manner described above to protect the items 404 fromtemperature variances within the container and may protect the productfrom damage. A second container lid 414 may be used to seal the secondcontainer 406.

Once positioned within the second container 406, the second container406 is then positioned in a third container 410. The third container 410may comprise of padding or insulating material 412 around the innerperiphery of the container 410. However, it will be appreciated thatthermal packs may be used in addition to or instead of padding orinsulating material 412. The insulating shipping materials made be madeof materials such as expanded polystyrene, urethane, vacuum panels, orother similar insulation materials. The third container 410 may alsohave a third container lid 416 a, 416 b, 416 c, 416 d to seal the thirdcontainer 410.

The first, second, and third containers, as well as the thermal packsmay all be reusable thereby adding to the efficiency and low cost of thepresent invention.

FIG. 5 is a block diagram of a method in accordance with an embodimentof the present invention. An absorbing pad may be placed in a firstcontainer at 500 to provide added protection from wetness or shock. Theitems may then be positioned in the first container above the absorbingpad at 502. However an absorbing pad does not need to be used and thefirst container may or may not be sealed.

At least one thermal pack may be filled with an alcohol at 504. Thethermal packs may then be positioned above and below the first containerat 506. The first container may then be enclosed in a second containerat 508 and the second container may be sealed at 510 to maintain thetemperature of the items at around 20° C.-24° C. The second containermay then be enclosed in a third container at 512. The third containermay contain a padding or insulating material around the inner peripheryof the container. However, it will be appreciated that thermal packs maybe used in addition to or instead of padding or insulating material. Thethird container may then be sealed at 514.

While embodiments and applications of this invention have been shown anddescribed, it would be apparent to those skilled in the art having thebenefit of this disclosure that many more modifications than mentionedabove are possible without departing from the inventive concepts herein.The invention, therefore, is not to be restricted except in the spiritof the appended claims.

1. An apparatus to thermally package an item, comprising: at least onecontainer substantially filled with an alcohol, wherein said alcoholundergoes a phase change.
 2. The apparatus of claim 1 wherein saidalcohol is a linear alcohol or a branched alcohol
 3. The apparatus ofclaim 1 wherein said alcohol has a purity of about 90%-100%.
 4. Theapparatus of claim 1 wherein said container is reusable.
 5. Theapparatus of claim 1 further comprising means for releasably lockingeach of said at least one container.
 6. The apparatus of claim 1 whereinsaid alcohol is 1-Dodecanol.
 7. The apparatus of claim 6 wherein the1-Dodecanol has a phase change at about 20° C.-24° C.
 8. The apparatusof claim 1 wherein said alcohol is 1-Decanol.
 9. The apparatus of claim8 wherein the 1-Decanol has a phase change at about 2° C.-8° C.
 10. Theapparatus of claim 1 wherein said alcohol comprises about 6 to 20 carbonatoms.
 11. A method for thermally packaging an item, comprising: fillinga container substantially with an alcohol; and freezing the container,wherein said alcohol undergoes a phase change.
 12. The method of claim11 wherein said alcohol is a linear alcohol or a branched alcohol. 13.The method of claim 1 wherein said alcohol has a purity of about90%-100%.
 14. The method of claim 8 wherein said container is reusable.15. The method of claim 8 wherein said alcohol is 1-Dodecanol.
 16. Themethod of claim 15 wherein the 1-Dodecanol has a phase change at about20° C.-24° C.
 17. The method of claim 11 wherein said alcohol is1-Decanol.
 18. The method of claim 17 wherein the 1-Decanol has a phasechange at about 2° C.-8° C.
 19. The method of claim 11 wherein saidalcohol comprises about 6 to 20 carbon atoms.
 20. A method for thermallypackaging at least one item, comprising: positioning the at least oneitem in a first container; placing at least one thermal pack above andbelow the first container; enclosing said first container within asecond container; and sealing said second container.
 21. The method ofclaim 20 further comprising: enclosing said second container within athird container; and sealing said third container.
 22. The method ofclaim 20 wherein said positioning further comprises sealing said firstcontainer.
 23. The method of claim 20 wherein said positioning furthercomprises: filling said at least one thermal pack substantially with analcohol; and freezing said at least one thermal pack, wherein saidalcohol undergoes a phase change.
 24. The method of claim 23 whereinsaid alcohol is a linear alcohol or a branched alcohol.
 25. The methodof claim 23 wherein said alcohol has a purity of about 90%-100%.
 26. Themethod of claim 23 wherein said alcohol is 1-Dodecanol.
 27. The methodof claim 26 wherein the 1-Dodecanol has a phase change at around 20°C.-24° C.
 28. The method of claim 23 wherein said alcohol is 1-Decanol.29. The method of claim 28 wherein the 1-Decanol has a phase change ataround 2° C.-8° C.
 30. The method of claim 23 wherein said alcoholcomprises about 6 to 20 carbon atoms.
 31. The method of claim 21 whereinsaid first, second, and third container and said thermal pack arereusable.
 32. The method of claim 21 wherein said third containerfurther comprises an insulating material surrounding an inner peripheryof said third container.
 33. The method of claim 21 wherein said thirdcontainer further comprises at least one thermal pack surrounding aninner periphery of said third container.
 34. The method of claim 20wherein said positioning further comprises placing at least oneabsorbing pad between said first container and said at least one item.35. The method of claim 20 wherein said placing further comprises matingeach of said at least one thermal packs.
 36. A system to thermallypackage at least one item, comprising: a first container to contain saidat least one item; a second container to contain said first containerhaving a first lid to seal said second container; and at least onethermal pack positioned above and below said first container within saidsecond container, wherein said thermal pack is substantially filled withan alcohol and wherein said alcohol undergoes a phase change.
 37. Thesystem of claim 36 further comprising: a third container to contain saidsecond container having a second lid to seal said third container. 38.The system of claim 36 further comprising a means for releasably matingeach of said at least one thermal packs.
 39. The system of claim 36wherein said first container further comprises a top lid to seal saidfirst container.
 40. The system of claim 36 further comprising anabsorbable pad positioned between said first container and said at leastone item.
 41. The system of claim 37 wherein said third containerfurther comprises an insulating material around an inner periphery ofthe third container.
 42. The system of claim 37 wherein said first,second, and third containers and said thermal packs are reusable. 43.The system of claim 36 wherein said alcohol is a linear alcohol or abranched alcohol.
 44. The system of claim 36 wherein said alcohol has apurity of about 90%-100%.
 45. The system of claim 43 wherein saidalcohol is 1-Dodecanol.
 46. The system of claim 45 wherein the1-Dodecanol has a phase change at around 20° C.-24° C.
 47. The system ofclaim 43 wherein said alcohol is 1-Decanol.
 48. The system of claim 39wherein the 1-Decanol has a phase change at around 2° C.-8° C.
 49. Thesystem of claim 43 wherein said alcohol comprises about 6 to 20 carbonatoms.
 50. A thermal container, comprising: a front surface opposite aback surface; a first side opposite a second side, said first and secondside having at least one mating member; and a top side opposite a bottomside; wherein said front surface, back surface, first side, second side,top side, and bottom side form a cavity within said thermal container.51. The apparatus of claim 50 wherein said top side further comprises anopening.
 52. The apparatus of claim 50 wherein said cavity issubstantially filled with an alcohol.
 53. The apparatus of claim 52wherein said alcohol is a linear alcohol or a branched alcohol, whereinsaid alcohol undergoes a phase change.
 54. The apparatus of claim 52wherein said alcohol has a purity of about 90%-100%.
 55. The apparatusof claim 52 wherein said alcohol is 1-Dodecanol.
 56. The apparatus ofclaim 55 wherein the 1-Dodecanol has a phase change at around 20° C.-24°C.
 57. The apparatus of claim 52 wherein said alcohol is 1-Decanol. 58.The apparatus of claim 57 wherein the 1-Decanol has a phase change ataround 2° C.-8° C.
 59. The apparatus of claim 52 wherein said alcoholcomprises about 6 to 20 carbon atoms.
 60. The apparatus of claim 50wherein said mating member further comprises at least one connector tocouple said thermal container to a second thermal container.
 61. Theapparatus of claim 50 wherein said top side and said bottom side furthercomprises at least one mating member.
 62. The apparatus of claim 61wherein said mating member further comprises at least one connector tocouple said thermal container to a third thermal container.
 63. Theapparatus of claim 50 wherein said front surface further comprises atleast one mating member.
 64. The apparatus of claim 50 wherein said backsurface further comprises at least one mating member.
 65. The apparatusof claim 63 wherein said mating member further comprises at least oneconnector to coupled said thermal container to a fourth thermalcontainer.
 66. The apparatus of claim 64 wherein said mating memberfurther comprises at least one connector to coupled said thermalcontainer to a fifth thermal container.